Packaging material and method and device for producing the same

ABSTRACT

A packaging material for cushioning an object packed in a container is disclosed herein. The packaging elements making up the packaging material may be made from sheets of paper, and be cup-shaped with a floor and thickened walls having irregular folds created by crushing the walls. Also disclosed herein is a method for manufacturing the packaging material that includes the steps of unrolling a paper roll, cutting the paper into paper sheets, pressing the cut paper sheets to form a cup, and crushing the walls of the cup towards the floor of the cup. A machine for implementing this method is also disclosed, and includes a mandrel for pressing the cut paper sheets, a sleeve for crushing the walls of the cup, and a stop block for holding the paper sheets.

CLAIM FOR PRIORITY

[0001] The present application claims priority of U.S. ProvisionalPatent Application Serial No. 60/430,874, filed Dec. 4, 2002, thedisclosure of which being incorporated by reference herein in itsentirety.

BACKGROUND OF THE INVENTION

[0002] A. Field of the Invention

[0003] The present invention relates generally to packaging material,and, more particularly, to a packaging material that protects objects bycushioning and absorbing the shock or pressure experienced by theobjects, and a method and device for producing the same.

[0004] B. Description of the Related Art

[0005] Various packaging materials and systems have been proposed in thepast. The primary conventional packaging material consists of polymerfoams or expanded synthetic materials. These materials have been usedsince they fill the irregular spaces formed between the packed objectand the packaging container. Unfortunately, such materials need to bemanufactured by specialist companies, and require large shipping andstorage space.

[0006] Other shock absorbing systems have been proposed, but are notadapted for filling the irregular spaces between the packed object andthe packaging container. For example, U.S. Pat. No. 3,244,347 and FrenchPatent No. 2 624 103 disclose systems for inner packing and cushioning,but which are limited to the comers of the packaging container. Otherreferences disclosing systems incapable of filing irregular spacesbetween the packed object and the packaging container include: EuropeanPatent Application No. 0 602 580, which implements a padding having alattice structure; European Patent Application No. 0 888 879, which usesa corrugated or pleated padding; and International Publication No. WO93/16940, which uses packing elements comprising preformed conicalpockets, the functional angle of the cone having specific limits.

[0007] U.S. Pat. No. 5,179,952 proposes packaging material made fromstrips folded like accordions. However, such materials make for poorinner packaging and are easily crushable since the strips more or lessoverlap one another.

[0008] German Patent Application No. 40 18 173 proposes protective innerpacking (or padding) and filling material comprised of hollow bodies inthe form of cylinders or prisms made of pre-punched sections whose endsare glued together or inserted into each other. These materials offerlittle resistance to crushing and flatten too readily.

[0009] Packaging materials in the shape of curvettes or cups formed frompaper sheeting have also been proposed. For example, U.S. Pat. No.5,595,811 discloses elements in the form of cup-like configurations withmore or less accentuated folding of the paper. The various folds coverthe entire floor of the cup-like configuration.

[0010] International Publication No. WO 94/07765 discloses packagingmaterial in the form of a die-shaped thimble having a flat bottom with adiameter of between 1.27 and 2.54 centimeters (cm), and a tubular wall.These die-shaped thimble cushioning elements are obtained by die-forminga sheet of paper by passing a mandrel through a form. The paper sheetdisengages from the mandrel by the natural expansion of the folds of thetubular wall after the mandrel has passed through the form.

[0011] European Patent Application No. 0 667 304 discloses a packagingmaterial having hollow bodies derived from strips similar to those usedin German Patent Application No. 40 18 173. However, these hollow bodiesmay also have longitudinal folds or a rigid floor that gives them apot-like shape. The longitudinal folds extend parallel to each otherfrom the pot floor.

[0012] The packing materials disclosed in U.S. Pat. No. 5,595,811,International Publication No. WO 94/07765, and European PatentApplication No. 0 667 304 exhibit poor resistance to crushing, notablyunder the effects of forces running transversely to the lateral walls,and they flatten easily. The rigid floor disclosed in European PatentApplication No. 0 667 304 improves resistance to crushing, but is stillinadequate. The small thimble configuration disclosed in InternationalPublication No. WO 94/07765 also improves resistance to crushing, butmanufacturing a large number of these thimbles, in view of theirsmallness, complicates the manufacturing process.

[0013] Thus, there is a need in the art for a packaging material thatprotects objects by cushioning and absorbing the shock or pressureexperienced by the objects, resists crushing, and is easilymanufactured.

SUMMARY OF THE INVENTION

[0014] The present invention solves the problems of the related art byproviding a packaging or packing material, and a method and machine forproducing the same. The packaging material is economical, inexpensive,simple to manufacture, and requires low volume for shipping and storage.The packaging material also resists crushing, provides good shockabsorbing qualities, and may be prepared with a starting material havinga relatively high density, low space requirements, high flameresistance, and safe to store.

[0015] The packaging material may be prepared from rolls of paper and,more particularly, high-resistance rolls of paper or still rolls ofcommon paper. The method of preparing the packaging material may beimplemented by the user of the packaging material or near the locationwhere the packaging material is to be used.

[0016] Further scope of applicability of the present invention willbecome apparent from the detailed description given hereinafter.However, it should be understood that the detailed description andspecific examples, while indicating preferred embodiments of theinvention, are given by way of illustration only, since various changesand modifications within the spirit and scope of the invention willbecome apparent to those skilled in the art from this detaileddescription. It is to be understood that both the foregoing generaldescription and the following detailed description are exemplary andexplanatory only and are not restrictive of the invention, as claimed.

BRIEF DESCRIPTION OF THE DRAWINGS

[0017] The present invention will become more fully understood from thedetailed description given hereinbelow and the accompanying drawingswhich are given by way of illustration only, and thus are not limitativeof the present invention, and wherein:

[0018]FIG. 1 is a schematic side elevational view of a machine formanufacturing a packaging material in accordance with an embodiment ofthe present invention;

[0019]FIG. 2 is a schematic side elevational view of a mandrel, asleeve, and a hollow cylinder of the machine shown in FIG. 1, whereinthe lateral walls of the paper making up a packaging element of thepackaging material of the present invention have not been crushed;

[0020]FIG. 3 is a schematic side elevational view of the mandrel,sleeve, and hollow cylinder of the machine shown in FIG. 1, wherein thelateral walls of the paper making up the packaging element of thepackaging material of the present invention are crushed by the sleeve toform the finished packaging material;

[0021]FIG. 4 is a schematic side elevational view of the mandrel,sleeve, and hollow cylinder of the machine shown in FIG. 1, wherein thefinished packaging element is freed from the hollow cylinder;

[0022]FIG. 5 is an exploded, perspective view of an arrangement whichcould either be the mandrel and sleeve of the machine shown in FIG. 1,or the sleeve and hollow cylinder of the machine shown in FIG. 1, suchan arrangement preventing the jamming of the paper in the machine;

[0023]FIG. 6 is a perspective view of a packaging element of thepackaging material in accordance with one aspect of the presentinvention;

[0024]FIG. 7 is a perspective view of a packaging element of thepackaging material in accordance with another aspect of the presentinvention, wherein the packaging element has a lower height and moreopen base or floor than the packaging element shown in FIG. 6;

[0025]FIG. 8 is a perspective view of a packaging element of thepackaging material in accordance with still another aspect of thepresent invention, wherein the packaging element has a larger base orfloor than the packaging element shown in FIG. 6; and

[0026]FIG. 9 is a perspective view of a container holding an object thatis packed by the packaging material of the present invention.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0027] The following detailed description of the invention refers to theaccompanying drawings. The same reference numbers in different drawingsidentify the same or similar elements. Also, the following detaileddescription does not limit the invention. Instead, the scope of theinvention is defined by the appended claims and equivalents thereof.

[0028] A. The Packaging Material

[0029] In a first embodiment, as best shown in FIGS. 6-8, the presentinvention relates to an inner packaging, packing, padding, and/orcushioning material that is made up of a plurality of packagingelements. The packaging material may consist of more than one, more thanten, preferably more than twenty, and possibly several tens or hundredsof the packaging elements. Each packaging element is preferably madefrom paper, and has an overall cup-like (or curvette) shape with acentral empty space, a floor 17, and a surrounding, folded lateral wall18. The lateral wall 18 of the packaging element is preferably thick,having an average thickness more than ten times greater than thethickness of the paper. As used herein, the terms “cup-like” or“curvette” indicate that there is a floor to the packaging element, asin any type of container. However, the folded wall 18 does not resemblethose of a conventional cup, as shown in FIGS. 6-8.

[0030] According to one aspect of the invention, the floor 17 of the cupis not folded but its wall 18 is folded in an irregular, zigzagconfiguration. This irregular, zigzag configuration may be obtained bycrushing a sheet of paper along its length, i.e., transverse to thethickness of the paper sheet, in the direction of the floor 17 of thecup.

[0031] According to another aspect of the invention, the folds of thewall 18 of the cup include a plurality of folds, generally more than tenfolds, and preferably more than twenty-five folds. The majority of thefolds may extend up to the floor 17 of the cup and, advantageously, theyoverlap each other or form angles of intersection with each other.

[0032] According to one feature of the invention, a significant portionof the folds, e.g., greater than 20% of them, and more preferably morethan 40% of them, but less than 95% of them, have a general orientationapproximately parallel to the plane representing the floor 17 of thecup. An orientation parallel to the floor 17 of the cup enables, asdescribed more fully below with reference to the manufacturing method ofthe cup, walls 18 to be created by crushing paper sheets in a directionsubstantially perpendicular to the floor 17 of the cup. Such folds areapproximately parallel and can form angles running up to forty-fivedegrees, from one side to the other, with the floor 17 of the cup.

[0033] The cup-shaped packaging element of the present inventionpreferably has a uniform surface, preferably the floor 17, that is flator rounded to enable an easily-readable inscription for advertising. Theoverall diameter (average) may be between one and fifteen centimeters(cm), and preferably between 2.6 and ten cm.

[0034] According to a preferred feature of the invention, the ratio ofthe volume of the packaging element to the surface area of the papernecessary to make the packaging element is within a range of 0.01 tofive cm³/cm², preferably from 0.05 to one cm³/cm², and more preferablyfrom 0.1 to one cm³/cm². The ratio of the volume of the packing elementrelative to the initial volume of paper necessary to make the packagingelement is generally between ten and three-hundred, preferably betweenforty and two-hundred, and more preferably between fifty andone-hundred.

[0035] According to another advantageous feature of the invention, thepackaging element may have a ratio of an average exterior diameter ofthe cylinder to the height of the wall 18 of between 0.2 and eight,preferably between 0.9 and six, and more preferably between 0.9 andthree. The ratio of the exterior diameter of the cylinder to the averagethickness of the lateral wall 18 may be between 2.1 and eight, andpreferably between 2.2 and six.

[0036] Each packaging element making up the packaging material of thepresent invention has excellent resistance to crushing, exterior shock,and various deforming forces. Avoiding deformations is important becausethey can cause a loss of the padding character of the packagingmaterial. The packaging material also has a superior cushioning effectand occupation rate of the empty spaces in the packing container. Afurther advantage of the packaging elements of the present invention isthat they do not have a tendency to become inserted in each other.

[0037] The use of rigid paper, or very rigid paper, is preferable withthe present invention, because it provides packaging elements moreresistant to crushing. The paper known by the name Kraft paper (astrong, high-performance wrapping paper) is particularly advantageousfor obtaining these results. Recyclable and/or recycled papers may alsobe used, however, non-recycled papers are preferred, especially thosenot having a natural tendency to unfold. The paper may be multilayered,but it is generally preferred, for efficiency and economy, to usesingle-layered paper.

[0038] FIGS. 6-8 show various types of packaging elements capable ofbeing produced in accordance with the teachings of the presentinvention. As shown in these FIGS., packaging element 11 includes afloor 17, and a central cavity formed between thick walls 18. Theoverall shape of the packaging element 11 is that of a thick-walled cupor curvette. These FIGS. also highlight the irregular thicknesses, andfolds of thick walls 18. Despite the irregular thicknesses of walls 18,an approximate average thickness may be determined for walls 18, as wellas an internal and external diameter of the cylinder formed by walls 18,as discussed above. The packaging element 11 shown in FIG. 7 has a lowerheight and more open base or floor than the packaging element 11 shownin FIG. 6. Whereas the packaging element 11 shown in FIG. 7 has a largerbase or floor than the packaging element shown in FIG. 6. FIGS. 6-8 areexemplary only, and other variations and sizes of packaging element 11may be realized in accordance with the present invention.

[0039]FIG. 9 is a perspective view of a container (19) holding an object(20) that is packed by a multitude of packaging elements 11 making upthe packaging material of the present invention. Preferably, themultitude of packaging elements 11 completely covers the object to bepacked, providing a cushion and shock absorber.

[0040] B. Method For Manufacturing The Packaging Material

[0041] The present invention also relates to a method for manufacturingthe packaging material described above. The method comprises a firststep of cutting a band of paper into a plurality of small paper sheets,and a second step of pressing the paper sheets through an aperture of aform or template, resulting in the formation of preliminary paper cupshaving edges with an overall tubular shape. The third step of the methodincludes crushing the walls of the paper cups in one directionsubstantially perpendicular to the axis of the tube of the preliminarypaper cups, and in a direction towards the floor of the cup. The varioussteps of the method of the invention may be executed successively,repetitively, and continuously.

[0042] Preferably, the aperture (or hollow channel) has a diameterapproximately equal to the diameter of the finished packaging element.Pressing is preferably done on a piece of paper cut from an unrolledroll of paper. The pressing step may be accomplished with a cylindricalmandrel having an axis of translation identical to that of the apertureof the form or template. The crushing step may be performed by acylindrical sleeve sliding along the mandrel.

[0043] The pressing and the crushing steps are preferably performedwithout jamming the paper between the cylindrical sleeve and the wallsof the aperture, and between the cylindrical mandrel and the cylindricalsleeve. In order to prevent the paper from jamming, beads, grooves, orserrations are preferably provided longitudinally on the cylindricalsleeve, the walls of the aperture, and the cylindrical mandrel. FIG. 5shows such an arrangement, described more filly below, which couldeither be the mandrel and the sleeve, or the sleeve and the aperture. Asshown, the beads, grooves, or serrations have corresponding shapes toenable sliding of the one in the other.

[0044] According to a preferred embodiment of the present invention, themethod comprises a first step of supplying paper in the form of a flatsheet (mono-layered or multi-layered, preferably mono-layered), wherethe paper supply directs the paper to a position for covering theaperture of the hollow channel. The first step preferably uses paper inthe form of a large flat sheet supplied by unrolling a roll of paper.This is particularly advantageous since storing of such paper rollsrequires little space and is much less flammable than packing materialmade of expanded polystyrene.

[0045] The method also includes a second step of cutting the paper alongparallel strips, preferably longitudinally, and a third step of cuttingthe parallel strips transversely to form small restricted area sheets(preferably rectangles or squares) of paper. The second and third stepsmay be performed simultaneously, continuously, or in inverted order(i.e., the third step precedes the second step). The method furtherincludes a fourth step of pressing the small paper sheets into theinterior of a hollow channel of a form or mold using a ramming orpressing mechanism (preferably, a mandrel pushing the small sheets attheir centers), until the small sheets have completely penetrated thehollow channel and the centers of the small sheets abut against a rigidsurface or stop block provided at the bottom of the hollow channel.

[0046] A fifth step of the method involves pushing the lateral parts ofthe small sheets in the direction of the stop block to produce amultiple, irregularly folded shape for the lateral parts. The methodalso includes a sixth step of removing the stop block to liberate thefinished packaging element from the hollow channel, and a seventh stepof causing the packaging element to exit from the hollow channel. Thefinal step of the method involves collecting the finished packagingelements.

[0047] The small sheets of paper used to make the packaging material ofthe present invention have a limited surface. As used herein, the term“limited surface” is understood to mean that the surface of the smallsheets is smaller than that of the initial large sheet since the largesheet has been cut once, and possibly twice. The limited-surface, smallsheets may have a rectangular, square, or circular shape, and may haveside dimensions (or the diameter in the case of a circle) between threeand forty cm, preferably between four and twenty-five cm, and morepreferably between five and twenty cm.

[0048] C. Machine For Manufacturing The Packaging Material

[0049] The present invention also relates to a machine for performingthe method described above and for making the packaging elements of thepackaging material described above. The machine for making the packagingelements of the present invention is generally shown in FIGS. 1-5. Asshown, the machine includes a mold or form 3 connected to a flat surface2, and having an aperture or hollow channel 15 provided therethrough.The machine further includes a mechanism for pressing 5 small sheets ofpaper 1 through hollow channel 15, and a mechanism for crushing 6lateral parts 16 (lateral walls of a preliminary cup) of the smallsheets of paper 1. A stop block 4 retains the paper sheets 1 in hollowchannel 15, and is arranged so that the paper sheets 1 are between thestop block 4 and the crushing mechanism 6.

[0050] The machine according to the present invention may also includesome or all of the following preferential characteristics. The pressingmechanism 5 may be a mandrel having a generally cylindrical shape, suchas polygonal, circular, or curvilinear, and preferably having ananti-jamming mechanism in the form of longitudinal serrations, grooves,or beads provided parallel to the axis of the cylinder. The pressingmechanism 5 may also be a cylinder that may slide into the interior ofthe crushing mechanism 6, as shown in FIGS. 1-4. For quality and safetypurposes, the cylinder of the pressing mechanism 5 may have a rounded,spherical, or ovoid bottom.

[0051] The crushing mechanism 6 may be a sleeve capable of sliding alongthe mandrel 5. The mandrel 5 and sleeve 6 may act successively to createthe preliminary cup and then, thereafter, to crush the walls 16 of thecup for creating the packaging element 11 of the present invention, asshown in FIGS. 2 and 3. Stop block 4 is moveable and may be withdrawn sothat the finished packaging element 11 may be removed from hollowchannel 15. The crushing mechanism 6 may also be in the form of acylinder or disk connected to one or several stems (or bars). The stemsor bars are used to move the disk and crush the paper sheets. Thecrushing mechanism 6 may also have the shape of a piston.

[0052] Preferably, the hollow channel 15 is cylindrical having a round,polygonal, regular, or irregular shaped base. A mechanism may beprovided that retracts stop block 4 to permit the finished packagingelement 11 to exit hollow channel 15. A mechanism for collecting thefinished packaging material may also be provided.

[0053] In order to prevent the paper from jamming, beads, grooves, orserrations are preferably provided longitudinally on the cylindricalsleeve 6, the walls of the hollow channel 15, and the cylindricalmandrel 5. FIG. 5 shows such an arrangement, where elements 7 and 8could either be mandrel 5 and sleeve 6, or sleeve 6 and hollow channel15. As shown, the beads, grooves, or serrations have correspondingshapes to enable sliding of the one in the other. The size and the shapeof the grooves, beading, or serrations may vary. However, in one aspectof the present invention, the size of the beads, grooves, or serrationsare between ½ millimeter (mm) and one cm, but sizes exceeding thesedimensions may also be provided. The beads, grooves, or serrations maybe disposed on more than half of the surfaces of the cylinders (hollowchannels 15, pushing mechanism 5, and crushing mechanism 6), preferablyover more than two-thirds of the surfaces, and more preferably over theentire surfaces.

[0054] The mechanism supplying the small sheets of paper 1 may include amechanism for supplying large paper sheets from a roll of paper 12, and,if appropriate, an unrolling mechanism 14 for unrolling the continuousroll of paper 12 so to create a large sheet. If required, a mechanismfor longitudinal cutting of the large sheet into parallel strips, and amechanism 13 for transverse cutting of the parallel strips into smallsheets of paper may be provided.

[0055] In one aspect of the invention, springs (or an equivalentstructure) may join pressing mechanism 5 to crushing mechanism 6. Thesprings bias pressing mechanism 5 to extend outside of crushingmechanism 6, providing a spatial offset between the end of pressingmechanism 5 and the end of crushing mechanism 6, as shown in FIG. 1. Bymaintaining pressing mechanism 5 in an offset position, pressingmechanism 5 is able to press the centers of the small sheets of paper 1prior to the crushing of the lateral walls 16 of the paper 1 by crushingmechanism 6. When pressing mechanism 5 abuts against stop block 4,crushing mechanism 6 impinges upon the springs (or equivalent structure)and pushes the lateral walls 16 of the paper sheets to crush the same,as shown in FIG. 3. The springs may be replaced with any equivalentstructure, such as, for example, motors that separately and successivelyactuate pressing mechanism 5 and crushing mechanism 6, etc.

[0056] The specific examples of the machine of the present inventionillustrated in FIGS. 1-4 in no way limit the scope of the presentinvention, but rather provide a better understanding of the machine andmethod of the present invention. FIG. 1 shows pressing mechanism 5 andcrushing mechanism 6 prior to pressing the small sheets of paper 1. Thehollow channel 15 is thus covered at one end by the small sheets ofpaper 1, and at the other end by stop block 4. The mechanism forpreventing jamming of the paper is present, although it is not shown inFIG. 1. The paper is rolled off from a roll of paper 12 by a mechanism14 for engaging and unrolling the paper, and sent towards the cuttingmechanism 13. From cutting mechanism 13, the paper 1 is provided overhollow channel 15 for pressing and crushing.

[0057]FIG. 2 depicts the step of the method of the invention where thepressing mechanism 5 has pushed the paper sheet 1 completely insidehollow channel 15, without jamming between crushing mechanism 6 andpressing mechanism 5, and up to the point where paper sheet 1 contactsor abuts stop block 4. The portion of paper sheet 1 contacting stopblock 4 becomes the floor of the cup of the packaging element of thepresent invention. At this stage of the method, crushing mechanism 6 hasnot crushed lateral parts 16 of paper sheet 1.

[0058]FIG. 3 shows the step of the method of the invention wherecrushing mechanism 6 has crushed lateral parts 16 of paper sheet 1. Atthis stage, the packaging element 11 of the present invention iscomplete, but has not been freed from the machine.

[0059]FIG. 4 shows the step of the method where the finished packagingelement 11 is freed from the machine by the pressing mechanism 5, and onretraction of stop block 4.

[0060] Although FIGS. 1-4 show only one pushing mechanism 5, crushingmechanism 6, hollow channel 15, etc. arrangement, the machine of thepresent invention may have a plurality of these arrangements runningsimultaneously or at different times so that packaging elements 11 maybe mass produced. The mass-produced packaging elements 11 may then becollected and stored for use as packaging material or directly placed inpackaging containers for use as packaging material.

[0061] It will be apparent to those skilled in the art that variousmodifications and variations can be made in the packaging material,method, and machine of the present invention and in construction of thepackaging material, method, and machine without departing from the scopeor spirit of the invention. Examples of such modifications andvariations were set forth above.

[0062] Other embodiments of the invention will be apparent to thoseskilled in the art from consideration of the specification and practiceof the invention disclosed herein. It is intended that the specificationand examples be considered as exemplary only, with a true scope andspirit of the invention being indicated by the following claims.

What is claimed is:
 1. A packaging element formed from a paper andsubstantially cup-shaped, the packaging element comprising: a floor; andan encircling lateral wall forming a central cavity with said floor,wherein said wall is non-uniform and made from folded portions of thepaper.
 2. A packaging element as recited in claim 1, wherein the papercomprises Kraft paper.
 3. A packaging element as recited in claim 1,wherein said wall has an average thickness greater than ten times thethickness of the paper.
 4. A packaging element as recited in claim 1,wherein said floor is substantially flat and the majority of the foldedportions of the paper making up said wall overlap each other, or formangles or intersections with each other.
 5. A packaging element asrecited in claim 1, wherein said wall comprises more than ten foldedportions of the paper.
 6. A packaging element as recited in claim 1,wherein said wall comprises more than twenty-five folded portions of thepaper.
 7. A packaging element as recited in claim 1, wherein the ratioof the volume of the packaging element to the surface area of the paperused to make the packaging element is in the range of 0.01 to fivecm³/cm².
 8. A packaging element as recited in claim 1, wherein the ratioof the volume of the packaging element to the surface area of the paperused to make the packaging element is in the range of 0.05 to onecm³/cm².
 9. A packaging element as recited in claim 1, wherein the ratioof the volume of the packaging element to the surface area of the paperused to make the packaging element is in the range of 0.1 to onecm³/cm².
 10. A packaging element as recited in claim 1, wherein theratio of the volume of the packaging element to the volume of the paperused to make the packaging element is in the range of ten tothree-hundred.
 11. A packaging element as recited in claim 1, whereinthe ratio of the volume of the packaging element to the volume of thepaper used to make the packaging element is in the range of forty totwo-hundred.
 12. A packaging element as recited in claim 1, wherein theratio of the volume of the packaging element to the volume of the paperused to make the packaging element is in the range of fifty toone-hundred.
 13. A packaging element as recited in claim 1, wherein theratio of the average exterior diameter of the packaging element cylinderto the height of the packaging element is between 0.2 and eight.
 14. Apackaging element as recited in claim 1, wherein the ratio of theaverage exterior diameter of the packaging element cylinder to theheight of the packaging element is between 0.9 and six.
 15. A packagingelement as recited in claim 1, wherein the ratio of the average exteriordiameter of the packaging element cylinder to the height of thepackaging element is between 0.9 and three.
 16. A packaging element asrecited in claim 1, wherein the ratio of the exterior diameter of thepackaging element to the average thickness of said wall is between 2.1and eight.
 17. A packaging element as recited in claim 1, wherein theratio of the exterior diameter of the packaging element to the averagethickness of said wall is between 2.2 and six.
 18. A method ofmanufacturing a packaging element, comprising: pressing a sheet of paperthrough an aperture of a template to form a tubular paper cup; andcrushing the walls of the tubular paper cup in a direction substantiallyperpendicular to the axis of the tube of the tubular paper cup to formthe packaging element.
 19. A method of manufacturing a packaging elementas recited in claim 18, wherein the sheet of paper is cut from anunrolled roll of paper.
 20. A method of manufacturing a packagingelement as recited in claim 18, wherein the pressing and crushing stepsare executed successively, repetitively and continuously.
 21. A machinefor manufacturing a packaging element, comprising: a mold having ahollow channel provided therein; a pressing mechanism for pressing apaper sheet into the hollow channel of said mold to form a preliminarycup; a crushing mechanism for crushing of the lateral walls of thepreliminary cup; and a stop block retaining the paper sheet so that thepaper sheet is between said stop block and said crushing mechanism. 22.A machine for manufacturing a packaging element as recited in claim 21,wherein said pressing mechanism comprises a mandrel in the shape of acylinder with a polygonal, circular, or curvilinear base; said crushingmechanism comprises a sleeve that is capable of sliding on the mandrel;and the mandrel and sleeve act successively to initially form thepreliminary cup and then subsequently crush the walls of the cup tocreate thick, non-uniform walls of the packaging element.
 23. A machinefor manufacturing a packaging element as recited in claim 21, whereinsaid stop block is moveable to allow the packaging element to exit fromthe hollow channel.
 24. A machine for manufacturing a packaging elementas recited in claim 22, wherein the mandrel and sleeve further includemating beads, grooves, or serrations running parallel to their axes toprevent the paper sheet from jamming between the mandrel and the sleeve.25. A machine for manufacturing a packaging element as recited in claim22, wherein the sleeve and hollow channel further include mating beads,grooves, or serrations running parallel to their axes to prevent thepaper sheet from jamming between the sleeve and the hollow channel. 26.A machine for manufacturing a packaging element as recited in claim 21,further comprising: a mechanism for unrolling a continuous paper roll tocreate a large sheet; and a mechanism for cutting the continuous paperroll into paper sheets.
 27. A packaging material comprising a pluralityof packaging elements, each packaging element being formed from a paper,being substantially cup-shaped, and comprising: a floor; and anencircling lateral wall forming a central cavity with said floor,wherein said wall is non-uniform and made from folded portions of thepaper.
 28. A system for protecting an object, comprising: a containerfor housing the object; and a packaging material comprising a pluralityof packaging elements provided in said container and around the objectto protect the object, wherein each packaging element is formed from apaper, is substantially cup-shaped, and comprises a floor, and anencircling lateral wall forming a central cavity with the floor, thewall being non-uniform and made from folded portions of the paper.
 29. Acontainer padded with a packaging material comprising a plurality ofpackaging elements, each packaging element being formed from a paper,being substantially cup-shaped, and comprising a floor, and anencircling lateral wall forming a central cavity with the floor, thewall being non-uniform and made from folded portions of the paper.